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Paper ID #23003
Development of a Virtual Reality Flight Simulator to Assist in the Design ofOriginal Aircraft
Dr. Dominic M. Halsmer P.E., Oral Roberts University
Dr. Dominic M. Halsmer is a Professor of Engineering and former Dean of the College of Science andEngineering at Oral Roberts University. He has been teaching science and engineering courses therefor 26 years, and is a registered Professional Engineer in the State of Oklahoma. He received BS andMS Degrees in Aeronautical and Astronautical Engineering from Purdue University in 1985 and 1986,and a PhD in Mechanical Engineering from UCLA in 1992. He received an MA Degree in BiblicalLiterature from Oral Roberts University in 2013. His current research interests involve the use if virtualreality for engineering education, the integration of faith and learning, contributions from the field ofengineering to the current science/theology discussion, reverse engineering of complex natural systems,and the preparation of scientists and engineers for missions work within technical communities.
Mr. John A. Voth, Oral Roberts University
John Voth is a current senior mechanical engineering student at Oral Roberts University. He will pursuehis PhD from the University of Minnesota after graduation.
Mr. Connor A. McCain, Oral Roberts University
Connor McCain is an undergraduate engineering student at Oral Roberts University.
Mr. Jordan David Reutter, Oral Roberts University
Jordan is Mechanical Engineering Student at Oral Roberts University Graduating in May 2018. He’sbeen involved with many projects such as The Hyperloop Competition and is currently interning with TheBoeing Company. He was primarily involved with the design and manufacturing of Team Soar’s flightsimulator serving as a design engineer.
Nathaniel Shay FraileyMatthew SamuelsonMr. David Ahrens, Oral Roberts University
c©American Society for Engineering Education, 2018
Development of a Virtual Reality Flight Simulator
to Assist in the Design of Original Aircraft (Work in Progress)
ABSTRACT
The undergraduate engineering curriculum is extremely challenging, largely due to the
complexity of the processes and concepts it introduces. One good way to handle this complexity
and assist students in learning about the development of engineered products is by providing
enhanced visualization of the processes and concepts involved. This has been recognized
recently by several researchers who are attempting to harness state-of-the-art virtual reality
experiences to improve the quality of engineering education. This has prompted one group to
write, "Virtual reality has grown up. Once an exotic field of computer sciences, it is now an
important topic for the engineers of tomorrow."1
The engineering research and development of a virtual reality flight simulator seems like a good
way to engage undergraduate engineering students with the up-and-coming field of virtual
reality. A multidisciplinary team of students at our university are pursuing this as their senior
capstone design project. The completed system will serve as an addition to the engineering labs
and assist future students with their design of original aircraft. With the help of a HTC Vive
virtual reality headset, the system will simulate the cockpit environment and faithfully respond to
pilot control inputs. The pilot will be strapped into a seat to be rigidly mounted atop a Stewart
platform, which will roughly simulate the dynamics of a student’s custom aircraft design.
This virtual reality aircraft motion simulator will be developed through extensive engineering
analysis that enhances engineering education both for those developing the simulator and for
those who will use it in design. First, the geometry of the simulator will be mathematically
analyzed and defined by the students, which will enable optimal geometries to be solved for to
maximize certain ranges of motion. Then, the dynamics of the system will be simulated using
MATLAB's Simulink technology to confirm the simulator's theoretical dynamic performance,
verify the ranges of motion from the students' mathematical analysis, and provide the necessary
specifications for the motors. Furthermore, structural analysis with SolidWorks will be used to
calculate the factor of safety of the system, which will help properly size the rotary actuators.
This engineering analysis of the simulator will function to increase exposure to principles of
aircraft design to both technical and non-technical students alike. The simulator is tailor-made to
accompany our university's Aircraft Design course. By pairing the our simulator with the course
engineering students will be able to learn about aircraft design, create their custom airplane using
X-Plane 11’s plane maker software, and then experience flying it on our simulator. This
immediate, immersive feedback enriches the students' knowledge of aircraft design and increases
interest in the topic. Additionally, the portable design of the simulator enables the system to
serve as an exciting advertisement to pre-college students considering the world of STEM
studies.
RECENT WORK IN VIRTUAL REALITY AND FLIGHT SIMULATION
As virtual reality is becoming more accepted and found to be useful in industry, these
experiences are finding their way into the engineering classroom and laboratory. The 2017 ASEE
Annual conference saw two papers that described how virtual reality is being used in
construction engineering education. Hao et al explain how virtual reality is used to recreate the
complex structures and construction techniques of dougong, a unique characteristic of ancient
Chinese architecture, in an environment where users can interact with objects with a high degree
of realism. Students benefit by examining structures and techniques via static images, dynamics
videos and VR interactivity, which are all compiled and integrated into a knowledge-based
system known as the Intelligent Dougong System with Virtual Reality (IDSVR). Multiple
presentation methods of dougong construction were then conducted with Autodesk 3DS MAX
and virtual simulations using the Oculus Rift.2 In another paper from last year, virtual reality was
used to illuminate ancient engineering and construction methods used in the Jinshanling region
of the Great Wall of China. A VR simulation using the Oculus Rift and an Xbox controller,
allows students to examine the construction process in a virtual environment. Thus, this study is
expected to permit students to immerse themselves in the virtual erection process of ancient
structures in a classroom setting.3
Flight simulators are also being used to enhance engineering education. To increase student
engagement and provide an enriched learning environment, Memon et al integrated a flight
simulator into a Flight Vehicle Performance course. Class performance revealed that students
enhanced their knowledge of aircraft stability and control through flight simulator experience.
Reflections from the students showed that they benefited greatly from the intuitive theoretical
learning through the use of flight simulator.4 Indeed, an earlier paper described the benefits of
integrating experience-based system simulation modules into a series of vehicle dynamics
courses, including a flight dynamics course. The authors claim that, “The benefits of imitating a
real process by way of simulation cannot be understated. The educational value of simulations
does not necessarily lie in the program itself, but rather, in the overall experience of the
simulation.”5 It is hoped that the following project can integrate a hands-on virtual reality
experience with a high-fidelity flight simulator to enhance student understanding of various
aspects of aircraft design and their impact on aircraft dynamics, stability, and performance.
To embark upon the complex endeavor of this project, an understanding of flight simulation first
had to be obtained by the team. At the beginning of this journey, the team had discovered that the
Stewart Platform was commonly used in the flight simulation field due to its ability to operate in
all six degrees of freedom. Immediately, they began to seek after highly academic sources on
Stewart Platform motion and the mathematics that governed it. They viewed sources such as
Detecting Singularities of Stewart Platforms6 and Stewart Platform with Fixed Rotary Actuators:
A Low-Cost Design Study.7 These sources gave great initial understanding of the motion that a
Stewart Platform can provide and the geometric constraints that must be upheld within its
construction; however, they primarily provided information that was beyond the scope of this
project and the mathematical understanding of the undergraduates students on the team. To gain
a simpler comprehensive grasp of the topic, the team began searching online forums for
assistance. This was highly beneficial to the project. The team discovered that there are many
projects that have some similarity to their own. Through forum sites such as XSimulator8 and
Motionsim,9 the team was able to observe not only successful Stewart Platform designs, but also
failures that had occurred in the making of those designs. Although these sites are nonacademic,
they provided very valuable information pertaining to the structural geometry and electrical
interfaces of the system. While on these sites, the team mainly observed builds by users
SilentChill and GA-Dawg from XSimulator and Motionsim respectively.
INTRODUCTION
A team of six engineering students, under the direction of two faculty members from Oral
Roberts University (ORU), is researching a new, innovative approach to deepen undergraduate
students’ practical understanding of aircraft design. These undergraduate seniors are developing,
fabricating, and fine-tuning an aircraft flight simulator, which, along with the help of VR
technology, will realistically produce the motion effects of flight. This simulator will allow
undergraduate engineering students taking an aircraft design course to accelerate the iterative
aircraft design process. Also, students will be able to experience a higher degree of project
completion, flying their custom virtual aircraft by taking the flight controls in their own hands.
In the Aircraft Design course at ORU, students learn how to design an experimental aircraft
using “correct” specifications according to theoretical values. This educational process will be
improved by providing further connection between actual flight handling and the supporting
aircraft design theory. This paper will demonstrate students’ attempt to bridge this gap by the use
of their VR aircraft motion simulator. By the end of the 2017-2018 academic year, students will
be able to accurately test their custom aircraft designs at intermediate and final stages, speeding
up the iterative aircraft design process. Also, students will have the capability to realistically
experience flight in their own custom designed aircraft, and further solidify their understanding
as to why their aircraft flies the way it does.
The scope of this project, however, reaches beyond just enhancing educational opportunities for
engineering students. Several passive flights will be programmed for the general public’s
immersion, exposing prospective and nontechnical students to the world of aircraft design.
Additionally, the intentional portability of this simulator opens the doors for this simulator to be
presented in multiple unique locations. As a whole, this project functions as a powerful tool of
engineering education, providing an immersive learning experience to many, regardless of the
individual’s prior level of knowledge.
DESIGN GOALS
The project has three specific goals that the team aims to complete by the end of the Spring 2018
semester. First and foremost, the team is building a Stewart platform to simulate flight with six
degrees of freedom and virtual reality equipment. Therefore, the platform will have to
realistically move with the chosen software so as to allow for the user to feel like they are
experiencing the motion of the airplane. The chosen software also needs to connect with virtual
reality so as to further immerse the person in the flight experience. Next, the goal of the project is
to partner with the Aircraft Design course taught by Dr. Halsmer. In doing so, the chosen
software will allow for the option of customizability, so that students can create/model their own
original aircraft and see how their designs produce unique flight dynamics. The student can then
sit inside their virtual plane in the simulator and experience what it would be like to pilot their
aircraft. This will allow for students to get a first-hand experience of how certain design
parameters truly affect the overall flight characteristics of aircraft.
In addition to these design goals, the last major goal of the project is to house the Stewart
platform within ORU’s virtual reality lab in the Global Learning Center. In addition to educating
engineering students, the simulator will also be used as a promotional tool, both for the
university and the engineering department, and allow it to be a resource for what other needs the
university might have for a Stewart platform. With this in mind, a few more practical design
goals are being pursued. First, the simulator must be safe enough for people of all ages and sizes
to ride in. Also, the platform must carry a professional look so that the university can showcase it
and people will feel confident to ride in it. In addition to all this, since most of those riding in the
simulator will not have experience in controlling the simulator, the software chosen must allow
for passive flights so that the user doesn’t have to understand the mechanics of flying but instead
can be led through a flight without their having to do much. These secondary goals will serve to
increase access to the experiences of flight, and aircraft design (and their relationship to STEM)
to a wide swath of the general public.
CAD: DIGITAL CONSTRUCTION
Due to the complex nature of the flight simulator’s Stewart platform geometry, the team decided
upon the use of Computer-Aided Design (CAD) to digitally construct the system. Because of its
accessibility and wide range of capabilities, SolidWorks® was chosen as the CAD design
software best suited for the teams needs. Seeing as the team’s design of the Stewart platform is a
quite intricate system of rotary actuated arms, many preliminary design iterations were
performed to gain an understanding of the range of motion that the simulator will undergo within
its movement, and the geometry that dictates its structure. These initial iterations were primarily
drafted around other flight simulator models. Once a general understanding of the platform
geometry and mechanics had been obtained through CAD modeling, the team turned its attention
to designing their own custom simulator.
The designing process began on paper, as many do. Geometric relationships pertaining to the
platform had to be determined before a unique system could be developed within the
SolidWorks® software. Considering the complexity of the complete structure, simplifications
and constraints were required so that the geometry of the system could be established. This was
accomplished by observing an isolated pair of the dual actuation arm subsystem in a planar
configuration and having motion confined to vertical heave. By defining the arbitrary constants
of total heave displacement, the expected seat height, and the theoretical center of gravity of a
seated man, a complete set of geometric relationships was then obtained. These calculations
resulted in a one-to-five length ratio for the lower and upper actuator arm pair, or, more
precisely, a 5.5 inch lower actuating arm and 27.5 inch upper actuating arm. Pairs of this
configuration were then aligned along each side of an equilateral triangle, such that there are six
pairs total. A visual of the isolated subsystem can be observed below in Figure 1.
Figure 1: Dual Actuating Arms Isolated in Heave (observing maximum and minimum position)
After using graphical and mathematical analyses to develop the dimensional basis of the
structure, components and assemblies were drafted within SolidWorks. The rods and lever arms
were first designed, and additional assemblies, such as the lower and upper platforms, followed.
To test and visualize the system geometry, multiple prototype models were manufactured
through 3D printing scaled down by a factor of ten. These models were developed to provide a
functional test and proof of concept to the team’s design. The scaled prototype models have
behaved as expected and have proven the aforementioned analysis as operational.
Once the final system geometry was established and tested, the geometric framework drafted in
SolidWorks was converted into actual industrial components that could be purchased. These
parts were designed and chosen alongside a selection of vendors taking into account both cost
and availability. The parts were modeled to the exact specifications of the vendor or in some
cases, the vendor provided a premade, dimensionally accurate CAD model available for
download. The system was organized into a variety of assemblies and sub-assemblies. All
necessary drill holes were also added to the system components, and a few larger bolts were also
added to increase the factor of safety. By using mates to fix the lever arms of the Stewart
Platform in key positions, the team is also able to use the model to prove the system geometry
that was mathematically established as well as predict and design around any geometric
collisions. Several simulation exercises were run to ensure structural stability in key locations.
The accurate model also allowed us to generate weight estimates for the system. With the model
complete, a full bill of materials was developed, vendors were identified, and materials were
purchased. Drawings and blueprints were drafted and printed to ensure accurate manufacturing
of each component. Developing a complete and accurate model of our system in SolidWorks is
an important part of the teams educational vision as it shows students the power of CAD design
software and gives them the opportunity to compare a virtual rendering with manufactured
reality.
ENGINEERING DESIGN
Early on in the design of the platform, it was decided that the best positioning of the connecting
rods to the upper platform would be to have them at the center of gravity. This would
theoretically ensure that the center of gravity would not be changing and all movement could be
based around a fixed point. To solve this, a study done Dr. John J. Swearingen was used called
Determination of Center of Gravity of Man.10
The following analysis, illustrated in Figure 2,
comes from this study.
Figure 2: The Center of Gravity of a Seated Man
From page 20: Trunk 115°, knees 145°, hands on lap.
From the figure above:
Thus, the vertical positioning for the location of the connection rods was set 11 inches above the
bottom portion of the chair so as to be closer to the center of gravity. Likewise, the chair was set
5.24 in back from the center of the connection rods to try to account for the offset position of the
center of gravity.
A unique complication within the design portion was the stress analysis of the members of the
system. With such a complicated inverse dynamics problem to solve for the individual torques
and forces being experienced, the team was running out of time for solving what needed to be
done so that they could order the motors, and other parts. So the team needed to find a simpler
way to estimate the stresses the individual components would experience so as to quicken the
process. The solution was to create a “worst case” nearly impossible scenario. Since the
maximum weight of the top of the platform will be 300 lbs, stress estimations were made by
applying the entire load to single members. Due to the setup of the platform, this scenario should
never occur, but if it can be proven that the design can hold up well under this case, then there
should be no chance of failure at any point during use. A factor of safety of 2 was implemented
for the analysis. Using these parameters, stress analysis has been conducted on the upper
connecting rods and bolts that connect to the Heim joints and are as follows.
Therefore, if the outer diameter of the connecting rods is greater than 1.093 in, there should be
no chance of failure due to buckling.11
The electrical design of the system was primarily structured after a Systems Engineering and
Computing professor whose alias is SixDegreesOfFlight on the reputable XSimulator forum. His
design was a compilation of previous designers on the website. The design comprises one
Figure 3. S-N Diagram
primary module which is repeated three times. This module consists of one Sabertooth 2x60 amp
drive, one Arduino Uno, two 24V 30A AC/DC Switching Power Supply Units (PSUs), two 12V
Lead-Acid Batteries to capture regenerative current from the Sabertooths, two 100A stud diodes
to protect the PSUs, one 60A resettable fuse, two 12V car relays, two 10k Ohm 10-turn
potentiometers for positional feedback, two 0.1uF noise-filtering capacitors placed on the
Arduino, and 24V DC permanent magnet motors which are each a part of a customized linear
actuator.
Figure 4: Foundational Electrical Module Design by SixDegreesOfFlight
There are several differences in our team’s design. First, we will not be using customized linear
actuators, but will instead be using solely the 24V DC permanent magnet motors with worm-
gearboxes attached. Secondly, the team will substitute each of the modules’ Arduino Unos for
one Arduino Mega microcontroller. This is done for both cost reasons and a compiled design of
the Arduino IDE program. Additionally, the team will have no need for the 10-turn
potentiometers but will instead use single turn potentiometers. This is also for simplicity and cost
reasons. Another variance in the designs which doesn’t provide much discrepancy regards the
input power. Because SixDegreesOfFlight is based in Australia, the design is powered using
standard Australian 240V AC power outlets, with a maximum current of 10 Amps. However, our
design is based in the USA, and will be using 120V AC power outlets with a maximum current
of 15 Amps for their system. Shown in Figure 5 is a block diagram of the current but evolving
state of the design.
Figure 5: Master Electrical Block Diagram
FABRICATION
The fabrication of the system is being performed fully in-house at our university. Each
component is first fabricated according to its dimensions and the specifications of its SolidWorks
drawing. This includes all cuts and holes or any other modifications. Once each component has
been prepped for assembly, the team will move into the assembly phase. By following a
directional assembly procedure, each part will be fastened together using bolts and mending
plates for aluminum parts, and welding for steel. The system will be split into three major
subassemblies: the upper platform, the rods, and the base. Once these sub-assemblies have been
assembled, they will be combined into the final system. Figure 6 is a current SolidWorks
rendering of the system, and Figure 7 is a photograph that shows the current state of assembly.
The system is on schedule to be fully functional by the end of the Spring 2018 semester.
Figure 6: SolidWorks Model of the Stewart Platform for the Custom VR Flight Simulator
Figure 7: Photograph Showing the Current Status of Stewart Platform Fabrication
EDUCATIONAL BENEFIT
To enrich the feedback within the aircraft design process, the design team will streamline a
process within pre-existing aircraft design software, X-Plane 11, so that students may easily
create their own custom aircraft based on an assortment of parameters that they select. These
parameters include: engine power, power loading, maximum coefficient of lift, aspect ratio, wing
taper ratio, stall speed, and much more through the inputting the necessary dimensions for each
part of the aircraft. Using Dan Raymer’s Simplified Aircraft Design for Homebuilders.12
and
Aircraft Design: A Conceptual Approach,13
also by Raymer, the Aircraft Design students will
select or define the necessary components to input into X-Plane 11’s “Plane Maker” software.
For each detail of the aircraft, the students will be able to draft or alter their aircraft inside the
program. Then, using the VR aircraft motion simulator that our team designed and built, students
will be able to experience flying their custom aircraft in an immersive, highly accurate manner.
Along with the Aircraft Design course, the motion simulator will be used to explain basic
aerodynamic properties in a course, called Introduction to Engineering, for freshman engineering
students. They will learn about concepts such as lift, drag, and the relationships formed by
altering the design of an aircraft by virtually flying multiple aircraft. The program will have
several aircraft with severe design conditions to enhance or hinder the performance of certain
characteristics to provide a clear visual representation. For example, the students would be able
to fly a traditional design as well as a design with an extremely exaggerated wingspan. Because
lift depends on the area of the wing, the students will notice the second aircraft takes off at a
much slower speed than the traditional design. Other example aircraft would have exaggerated
fuselage diameters to explain drag, or even altered airfoil shapes to show the different factors
within airfoil design. The students would first receive a lecture to discuss the properties being
exhibited, and then allowed to schedule time to operate the motion simulator.
In addition to these technical applications of the motion simulator, several passive flights will be
programmed into the system, allowing prospective or non-technical students to experience
realistic aircraft flight. Passive flights allow anyone to experience the feeling of flying the
uploaded aircraft without the need to learn any of the control aspects. Such ventures are pre-
specified by the software and include takeoff, a short flight around the airport, and landing. This
additional application of the simulator increases interest, experience, and enthusiasm in
aerospace design to a wide audience, presenting STEM studies in an exciting light and providing
the university with an excellent recruitment tool. Not only will the current engineering students
benefit from the motion simulator, but the university as a whole will be able to use the project as
a representation of the scholastic excellence of the university. With the motion simulator located
inside the Global Learning Center at ORU, school field trips, university assessments, and
prospective student visits will all be able to watch and operate the educational tool being
designed by ORU engineering students.
FLIGHT SIMULATOR ASSESSMENT
In order to provide a complete assessment for the project, the design team will execute each of
the design goals as part of their senior design project. As previously specified, for a successful
project, they will develop a Stewart platform with six degrees of freedom and virtual reality
compatibility, clear applications for the Aircraft Design coursework, and permanent residence in
the virtual reality lab at the Global Learning Center. The latter goal separates into three specific
categories: the simulator must be safe for all ages and sizes as specified, model a professional
appearance, and provide the opportunity for passive flight. If all of these goals have been met,
the project can be considered successful.
EDUCATIONAL ASSESSMENT PLAN
The ORU Aircraft Design course will be taught again to upper division undergraduate
engineering students in the 2018-2019 academic year. It is planned to utilize the custom VR
flight simulator to assist in motivating students during their aircraft design projects, and provide
additional insight into the aircraft design process. After students get an idea of the size of their
original aircraft, by estimating the power loading, wing loading, drag, lift-to-drag ratio and fuel
fraction, the take-off weight can be approximated. This is followed by engine sizing and
selection, wing geometry and placement, airfoil selection and tail geometry and sizing. Before
too long, the student will be able to “rough out” their original aircraft in X-Plane by specifying
all the necessary design parameters. This will give students the opportunity to take their first
draft aircraft on its virtual maiden voyage. (Of course, it will be helpful if they have some kind of
flight performance baseline with which to compare. For this reason, every student will be
required to spend a certain amount of virtual flight time in a standard trainer, such as a Cessna
150, prior to trying out their designs.) Virtual flight performance can then be compared to
predicted/desired performance and appropriate design modifications made. Multiple design
iterations are expected until students are satisfied with performance and the resulting designs.
Since this will be the first time to use the custom VR flight simulator in the Aircraft Design
course, student learning in this course will be compared to student learning previously taught
Aircraft Design courses. Exam and final project performance will be compared on an inter-
course absolute scale to see if the understanding of aircraft design has improved since the
introduction of the simulator. Survey data will also be collected from students in an effort to
assess motivation, enjoyment, learning, skill and confidence in aircraft design.
CONCLUSION
This paper has demonstrated the promise of using student-led innovation to improve the
educational experience of engineering students. From its inception, this project has been team-
focused and interdisciplinary, and it has provided a wonderful learning experience for the six
engineering students involved. They have had much experience in applying their theoretical
knowledge from class into the practicality of the build, gaining invaluable problem solving skills
along the way. But most excitingly, once this project is completed in a few weeks, the motion
simulator will benefit engineering and non-technical personnel alike for many years to come.
The students of this project cannot wait to conclude the project soon so that their efforts may
make engineering education more appealing and inviting. They are proud of their work and
excited that they have been making a positive contribution to their learning environment.
BIBLIOGRAPHY
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